ModelTypeGear Ratio

Oil

Weight (Dry)

SECTION 5B

MANUAL TRANSMISSION

TABLE OF CONTENTSSpecifications. . . . . . . . . . . . . . . . . . . . . . . . 5B-1

General Specifications . . . . . . . . . . . . . . . . . . 5B-1Fastener Tightening Specifications . . . . . . . . . 5B-2

External View . . . . . . . . . . . . . . . . . . . . . . . . 5B-3Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-3Power Flow . . . . . . . . . . . . . . . . . . . . . . . . . 5B-4Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-5

Will not Shift (Control Lever Moves) . . . . . . . . 5B-5Hard Shift or Control Lever Will not Move IntoGear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-5Gears Crash When Shifting . . . . . . . . . . . . . . 5B-5Transmission Jumps Out . . . . . . . . . . . . . . . . . 5B-6Transmission Locked in One Gear . . . . . . . . . 5B-6Transmission Noise . . . . . . . . . . . . . . . . . . . . . 5B-6Transmission Leakage . . . . . . . . . . . . . . . . . . 5B-7

Diagnosis Table . . . . . . . . . . . . . . . . . . . . . . . 5B-8Component Locator . . . . . . . . . . . . . . . . . . . 5B-9Maintenance and Repair . . . . . . . . . . . . . . 5B-11On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 5B-11

Shift Control Cable . . . . . . . . . . . . . . . . . . . . 5B-11Transmission . . . . . . . . . . . . . . . . . . . . . . . . 5B-14

Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . 5B-17Major Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-17Main Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-27Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-32Counter Shaft . . . . . . . . . . . . . . . . . . . . . . . . 5B-34Extension Housing . . . . . . . . . . . . . . . . . . . . 5B-35Shift Cover . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-36Inspection of Components . . . . . . . . . . . . . . 5B-40Pre-Installation Checks . . . . . . . . . . . . . . . . . 5B-45

SPECIFICATIONSGENERAL SPECIFICATIONS

Application DescriptionT5WC

Floor Change3.97 : 12.34 : 11.46 : 11.00 : 10.85 :13.71 : 1

ATF DEXRON II / III3.4 L

Check : Every 15,000km, Replace : Every 50,000km33kg

1st2nd3rd4th5th

ReverseSpecificationCapacity(litre)

Change Interval

NoticeAdd LUBRIZOL (280cc) in oil after overhauling.

5B-2 MANUAL TRANSMISSION

FASTENER TIGHTENING SPECIFICATIONSApplication

TransmissionOil Filler PlugTransmission Mounting Bolt (Housing)Oil Drain PlugFront Propeller Shaft (T/C)Rear Propeller Shaft (T/C)Cross Member Bolt (Center)Cross Member Bolt (Side)

Control CableShift Lever Bolt

N m

2577 - 87

2581 - 8970 - 9021 - 3562 - 93

20 - 30

MANUAL TRANSMISSION 5B-3

EXTERNAL VIEW

GEAR TRAIN

5B-4 MANUAL TRANSMISSION

POWER FLOW

MANUAL TRANSMISSION 5B-5

CheckClutch not releasing.Improper or low transmission oil.Shift or shift rail binding.

Binding of sliding synchronizers or gears.

If reverse only, faulty backup switch.Worn or damaged flywheel pilot bushing.

CheckControl lever assembly broken or damaged.Damaged offset lever, shift fork, selector place orselector arm.

DIAGNOSISWILL NOT SHIFT(CONTROL LEVER MOVES)

ActionReplace control lever and housing assembly.Remove extension, adapter or case cover.Check or replace damaged parts.

HARD SHIFT OR CONTROL LEVER WILL NOT MOVE INTO GEAR

ActionAdjust or replace clutch.Add or replace with specified oil.Remove extension, adapter or case cover.Check or replace damaged parts.Remove extension, adapter or case cover.Check synchronizers and gears and replacedamaged parts.Check or replace backup switch.Replace pilot bushing.

GEARS CRASH WHEN SHIFTING

CheckEngine idle speed too high.Damaged or faulty clutch.Pilot bearing between input shaft and output shaft binding.Damaged synchronizer.Bell housing misaligned.Damaged gear(s).Worn or damaged flywheel pilot bushing.

ActionAdjust idle speed to specified speed.Adjust or replace clutch.Replace or check roller bearings.Check or replace synchronizer parts.Align bell housing and bore.Check or replace gear(s).Replace pilot bushing.

5B-6 MANUAL TRANSMISSION

CheckLoosened transmission or flywheel housing bolts,improper alignment.Synchronizer damaged or excessively worn.Blocking ring damaged, worn index slots or frictionsurfaces worn or damaged.Excessive countershaft end play.

Worn or damaged fork due to loosened shaft, rail orshifting fork.

TRANSMISSION JUMPS OUTAction

Tighten bolts to specified value. Realign if necessary.

Check or replace synchronizer parts.Check or replace blocking ring.

Check worn or damaged parts. Adjust shim thicknessusing roller bearings if necessary.Check for wear or damaged. Replace worn ordamaged parts.

CheckFork or offset lever loose on shaft or rail.

Worn or damaged forks, offset lever, shaft or rail.

Worn or damaged synchronizer.

Worn or damaged gears.

TRANSMISSION LOCKED IN ONE GEARAction

Replace extension, adapter or case cover. Check orreplace loose parts on shaft or rail. Replace roll pin(s).Remove extension, adapter or case cover. Check forwear or damaged. Replace damaged parts.Check worn or damaged synchronizer parts andreplace if necessary.Check worn or damaged gears and replace if neces-sary.

CheckImproper or low transmission oil.Loose bolts or other attaching parts.Improper flywheel housing to engine crankshaftalignment.Noisy transmission bearing.

Noisy gears.

TRANSMISSION NOISE

ActionAdd or drain and replace with proper oil.Tighten as specified.Realign correctly.

Check bearings, bearing rollers and parts for wear ordamage.Replace if necessary.Check for worn or damaged gears(including speedometer gear).Replace if necessary.

MANUAL TRANSMISSION 5B-7

TRANSMISSION LEAKAGECheck

Leakage from transmission.Vent or breather clogged.Too much oil.Loose bolts at sealing faces.Improperly applied sealant.

Worn or damaged oil seal.

ActionClean all exposed surfaces, then check for leaks.Clean or replace vent or breather.Check oil level.Tighten as specified.Clean leaking surfaces.Reapply sealant.Replace oil seal.

5B-8 MANUAL TRANSMISSION

1 Shift Hop-out 2 Shift Gear Crash

3 Shift Block-out 4 Hard Shift

5 Noise in Reverse Gear6 Noise in 5th Gear 7 Noise in 4th Gear

8 Noise in 3rd Gear 9 Noise in 2nd Gear

10 Noise in 1st Gear 11 Noise in All Speeds

12 Leak at Transmission Rear Part 13 Leak at Transmission Center Part

14 Leak at Transmission Front

DIAGNOSIS TABLE

Condition

Possible Faulty PartTransmission CaseExtension HousingShift Cover / Shift ShiftShift Control LeverInput Bearing RetainerInput Gear Set3rd Speed Gear Set2nd Speed Gear SetReverse Speed Gear Set1st Speed Gear Set5th Speed Gear SetClutch Housing and Release DeriveCrankshaft Pilot Bushing and Release BearingInput BearingMain Shaft Input BearingMain Shaft Thrust Bearing3rd Speed Gear Bearing2nd Speed Gear Bearing1st Speed Gear BearingReverse Idler Gear BushingCounter Shaft Front BearingCounter Shaft Rear BearingCounter Shaft Thrust Bearing5th Speed Drive Gear BearingSlip Yoke BushingSlip Yoke SealSpeedometer Drive / Driven GearsSpeedometer Driven Gear HousingInput Shaft Seal1 - 2 Synchronizer Assembly3 - 4 Synchronizer Assembly5th Synchronizer AssemblyRing Oil SealT/C Front Face

MANUAL TRANSMISSION 5B-9

COMPONENT LOCATOR

5B-10 MANUAL TRANSMISSION

1 Filler/Drain Plug2 Shift Mechanism Cover3 Shift Shaft Lever4 Outer Select Lever5 Inner Select Lever6 Offset Control Lever7 Bias Spring8 Bolt9 Pin

10 Washer11 Bolt12 Bolt13 Extension and Plate Assembly14 O-Ring & Steel Ring15 Oiling Funnel16 Bolt17 Alignment Bolt18 Pin19 Shift Shaft20 3/4 Shift Fork21 1/2 Shift Fork22 Insert23 Selector Arm Assembly24 Interlock Plate Assembly25 Selector Plate26 O-ring27 Plug28 Case Cover29 Retaining Ring30 Pivot Pin31 Back-up Switch32 5/Reverse Shift Lever33 Snap Ring34 5th Synchronizer Retainer35 5th Synchronizer Assembly36 Synchronizer Spring37 Synchronizer Assembly

38 Insert39 Synchronizer Hub40 Roll Pin41 5th Shift Fork42 Insert43 Shift Rail Assembly44 Blocking Ring45 5th Speed Drive Gear46 Snap Ring47 Speed Gear48 Speed Gear Clip49 Bolt50 Input Bearing Retainer51 Oil Seal52 Shim53 Bearing Cup54 Bearing Cone55 Input Shaft56 Roller Bearing57 Spacer58 Thrust Bearing59 Thrust Bearing Race60 5th Speed Driven Gear61 Bearing Cup62 Bearing Cone63 1st Speed Gear64 Bearing Sleeve Assembly65 A. Bearing65 B. Bearing65 C. Spacer66 Sleeve67 Blocking Ring Assembly68 3/4 synchronizer Assembly69 Synchronizer Spring70 Synchronizer Sleeve71 Insert72 Synchronizer Sleeve

73 3rd Speed Gear74 Needle Bearing75 Spacer76 Snap Ring77 Thrust Washer78 2nd Speed Gear79 2nd Speed Gear Bearing80 Spacer81 Output Shaft Assembly82 Retaining Ring83 Thrust Washer84 Inner Cone85 Outer Cone Race86 1/2 Blocking Ring87 Spring Gear88 Reverse Sliding Gear89 Insert Gear90 Pin91 Shaft and Hub Assembly92 Spring93 Pin Fork and Reverse Roller

Assembly94 Bolt95 Rear Bearing Retainer96 Shim97 Roll Pin98 Reverse Idler Shaft99 Reverse Idler Gear Assembly

100 O-ring101 Bearing Cup102 Bearing Cup Assembly103 O-ring104 Bearing Cup105 Bearing Cone106 Counter Shaft Gear107 Transmission Case Assembly

MANUAL TRANSMISSION 5B-11

MAINTENANCE AND REPAIRON-VEHICLE SERVICE

SHIFT CONTROL CABLE

1 Shift Lever Assembly2 Bolt ...................................................... 20-30 Nm3 Select Cable4 Shift Cable5 Snap Pin6 Snap Pin7 Transmission8 Shift Cable

9 Select Cable10 Clip11 Clip12 Snap Pin13 Snap Pin14 Protector15 Washer

5B-12 MANUAL TRANSMISSION

Removal & Installation Procedure1. Position the shift lever in neutral and remove the knob.

2. Remove the screw from the console box side and removethe shift lever cover.

3. Disconnect the cables by removing the snap pins from thecontrol cable connections to the select lever and shift lever.

4. Remove the shift lever an cable mounting snap pin and

washer of the select lever.

MANUAL TRANSMISSION 5B-13

5. Pull out the clip from the bracket and remove the shift cableand select cable.

6. Installation is reverse order of the removal.

Inspection Procedure1. The shift lever should be positioned in neutral.2. Apply liquid gasket on the cable contact surface.3. Keep 130 mm between the center of the cable end-eye

and floor.

NoticeIf necessary, adjust the adjust nut.

Standard 130 mm

5B-14 MANUAL TRANSMISSION

TRANSMISSIONPreceding Work : Removal of the shift control cable

1 Clutch Housing2 Oil Filler Plug ............................................ 25 Nm3 Transmission Assembly4 Back-up Switch5 Washer6 Bolt ...................................................... 77-87 Nm7 Oil Drain Plug ............................................ 25 Nm8 Bolt ...................................................... 81-89 Nm9 Washer

10 Front Propeller Shaft11 Transfer Case Assembly

12 Speedometer Cable13 Rear Propeller Shaft14 Washer15 Bolt ...................................................... 70-80 Nm16 Cross Member17 Washer18 Bolt ...................................................... 21-35 Nm19 Washer20 Bolt ...................................................... 62-93 Nm21 Breather Hose

MANUAL TRANSMISSION 5B-15

Removal & Installation Procedure1. Disconnect the negative terminal from the battery.2. Lift up the vehicle and fix it safely.3. Remove the drain plug from the transmission housing and

drain the oil. Reinstall the drain plug.Installation Notice

Tightening Torque 25 Nm

4. Disconnect the back-up switch connector.

5. Remove the breather hose.

6. Remove the speedometer connector and other wiringharnesses and connectors.

5B-16 MANUAL TRANSMISSION

7. Remove the front and rear propeller shafts from thetransfercase.Installation Notice

Tightening Torque81 - 89 Nm70 - 90 Nm

FrontRear

8. Support the transmission on an suitable jack.Unscrew the center mounting nuts and each sidesmounting bolts and remove the cross member.Installation Notice

9. Remove the transmission mounting bolts.Installation Notice

Tightening Torque (1)Tightening Torque (2)

21 - 35 Nm62 - 93 Nm

10. Move the transmission jack backward careful anddisengage the transmission input shaft from the engine.Remove the transmission.

11. Installation should follow the removal procedure in thereverse order.

Tightening Torque 77 - 87 Nm

MANUAL TRANSMISSION 5B-17

UNIT REPAIRMAJOR UNITPreceding Work : Removal of the transmission

Removal of the transfer case

Disassembly Procedure1. Install the removed transmission into a fixture.2. Remove the drain plug and drain the oil. Using a 13 mm

wrench, remove the clamp bolt and position the offset leverin the 3-4 position of neutral.NoticeRemoval of the offset lever in a position other than 3-4 ofneutral will be difficult.

3. Using a pin punch and a hammer, remove the roll pin toremove the shift lever from the offset lever.

4. Using a 15 mm wrench, remove the 8 bolts from the extensionhousing.

5. Separate the extension housing from the case and shiftcover.Separate the offset lever from the shift.NoticeDo not remove the offset lever while the extension housingis still assembled to the case.

6. Remove the offset lever from the extension housing withthe detent ball and spring.

7. Remove the roll pin from either the offset lever or extensionhousing.

5B-18 MANUAL TRANSMISSION

8. Remove the counter shaft thrust race and bearing.

9. Carefully remove the oiling funnel from the end of thecounter shaft.

10. Using a 10 mm wrench, remove the 10 bolts from the shiftcover.NoticeFor assembly, note the location of the two bolts.

11. Lift up the shift cover after sliding it toward the drain plugabout 3 cm. At this time remove sealer bond.

12. Using a needle nose pliers, remove the 5-R lever clip.

MANUAL TRANSMISSION 5B-19

13. Using a 21 mm wrench or a T-50 bit, remove the 5-R leverpivot bolt.NoticeApply sealer bond to this bolt during assembly.

14. Using a 22 mm wrench, remove the back-up lamp switchfrom the 5-R lever side.NoticeApply sealer to the threads.

15. Pull out the 5-R lever out of the transmission.

16. Using a snap ring pliers, remove the 5th synchronizer snapring from the end of the counter shaft.

17. Remove the 5th synchronizer assembly with its fork andrail assembly from the counter shaft.

5B-20 MANUAL TRANSMISSION

18. Remove the slip yoke snap ring from the main shaft.

19. Remove the 5th speed drive gear snap ring from the mainshaft.

20. Make alignment marks on the case and input bearingretainer and remove the 4 input shaft bearing retainer bolts,using a 13 mm wrench.NoticeApply sealer on these bolts during assembly.Remove the input bearing retainer with the bearing outerrace and shim.

21. Remove the input shaft from the case by rotating it untilthe flat surface appears.

22. Remove the following parts from the input shaft.4th speed gear blocking ring.Main shaft thrust race and bearing.Main shaft pilot bearing rollers (15 rollers).

NoticeBe careful not to dissipate the pilot bearing rollers.

MANUAL TRANSMISSION 5B-21

23. Remove the main shaft in 2 steps.To remove the rear bearing outer race, push the mainshaft rearward.

Tilt and lift the main shaft from the case.

24. Remove the reverse fork and spring from the case.

25. Remove the counter shaft as follows:Using a punch and hammer, pry up the lock tabs.Using a 13 mm wrench or T-40 bit, remove the 4 bolts.Remove the retainer and shim from the case.Push the counter shaft rearward to remove the rearbearing outer race.

5B-22 MANUAL TRANSMISSION

26. Using a pin punch and a hammer, remove the roll pin fixedon the reverse idler shaft.

27. By pushing the reverse idler shaft rearward and out of thecase, remove the reverse idler gear and O-ring.

28. Using a puller, remove the rear bearing assembly from thecounter shaft.

MANUAL TRANSMISSION 5B-23

Assembly Procedure1. Using a hydraulic press and a supporting tool, press the

counter shaft rear bearing into the case. Be sure that thesupporting tool inside of the case should support the countershaft.

2. Without the shim, install the retainer and counter shaft rearbearing outer race. Tighten the 4 retainer bolts.

3. Place a dial indicator on the case and measure countershaft end play by moving up and down.

4. Select a shim which is the same thickness as the indicatorrearing (up to 0.004 inch) and assemble it.

5. When the end play is correctly adjusted, remove the countershaft rear bearing retainer and outer race.

6. Using a pin punch and rubber hammer, install the reverseidler shaft, gear and O-ring.

Tightening Torque 20 Nm

5B-24 MANUAL TRANSMISSION

7. Install the counter shaft rear bearing outer race, shim andretainer.

Tightening Torque 39 - 52 Nm

Using a punch and hammer, bend the lock tabs on theretainer.

8. Install the following parts :Install the main shaft into case.Install the main shaft rear bearing outer race into therear of the case.Install the 4th speed blocking ring onto the front of themain shaft.Install the input shaft onto the front of the main shaft.Install the input bearing retainer without shim onto thefront of the case.Using a torque wrench, tighten the 4 bolts.

9. Install the 5th speed drive gear and blocking ring on thecounter shaft.

10. Install the 5th synchronizer and rail/fork.

11. Install the 5th synchronizer snap ring and oiling funnel.

12. Align the slots of the lever with the rollers of the reversefork and 5th shift rail. Apply sealer on the 5-R lever pivotbolt and install it into the case.

Tightening Torque 28 Nm

13. Using a needle nose pliers, install the 5-R lever clip.

MANUAL TRANSMISSION 5B-25

14. Using a needle nose pliers, install the reverse fork springto its pin inside the case. Check the operation of the 5-Rshift mechanism at this time.

15. Using a snap ring piers, install the slip yoke snap ring ontothe end of the main shaft.

16. Make sure that the 1-2 and 3-4 synchronizer sleeves and5-R shift lever are in neutral position.

17. Align the holes the case and cover with alignment-typebolts. Tighten the 10 bolts.

18. Apply ‘RTV’ sealant on the sealing surface of the extensionhousing.

19. Apply grease on the detent/guide plate in the extensionhousing. Install the detent ball in the 3-4 position.

20. Place the detent spring and offset lever in the extensionhousing and push the extension against the case and shiftcover.

5B-26 MANUAL TRANSMISSION

21. Completely compress the detent spring.

22. To install the extension housing to the case, apply sealerto the top two bolts and tighten them and tighten the 6bolts.

23. Apply sealer to the back-up lamp switch and drain plugand tighten them.

24. Using a hammer, install the offset lever-to-shift roll pin.

25. Turn the transmission case reversely and place a dialindicator on the extension housing. Move the input andmain shift up and down and measure end play. Select ashim which is the same thickness as the measurement (±0.001 inch). After shim installation, the end play should be‘0’.

26. Remove the input bearing retainer and do the following :Install the adjusting shim behind the input bearing outerrace in the retainer and if 2 shims are used, install thethinner one in first.Install the retainer to the case and tighten the bolts.If end play is not ‘0’change the shim again.Apply RTV sealant to the sealing surface of the retainer.Apply sealer to the 4 retainer bolts and tighten them.

27. Remove the fill plug.

28. Remove the transmission from the holding fixture and installit to the vehicle.

29. Clean the sealing surface of the shift control lever.

30. Install the control cables to the shift lever.

MANUAL TRANSMISSION 5B-27

MAIN SHAFTDisassembly Procedure1. For correct reassemble, place an alignment mark on the 3-

4 Synchronizer hub and sleeve.

2. Using a hydraulic press and puller plate, remove the 3-4Synchronizer assembly and the 3rd speed gear.

3. Remove the 3rd speed gear bearing and spacer.

4. Using a snap ring pliers, remove the 2nd speed gear snapring.

5. Remove the 2nd speed gear thrust washer.

6. Remove the 2nd speed gear, bearing and spacer.

5B-28 MANUAL TRANSMISSION

7. Using a screwdriver, remove the spiral retaining ring.

8. Remove the thrust washer and three-piece 2nd speedblocking ring assembly.

9. For correct reassembly, place an alignment mark on the1-2 synchronizer hub and sleeve.

10. Remove the 1-2 synchronizer sleeve from the hub withfollowing parts :

The anti-rattle ball and spring.The three keys.One of the 3 springs.

11. Using a hydraulic press and puller plate, remove the 5thspeed driven gear from the main shaft.

MANUAL TRANSMISSION 5B-29

12. Remove the main shaft rear bearing assembly from theshaft.

13. Remove the 1st speed gear and bearing.

14. Remove the inner race.

15. Remove the tree-piece 1st speed blocking ring assemblyand remaining synchronizer spring.

16. Check and clean all removed parts and replace ifnecessary.

5B-30 MANUAL TRANSMISSION

Assembly Procedure1. When assemble the synchronizer, make sure that the hubs

and sleeves are matched and the 3 keys are installedproperly. Also align blocking rings with keys duringinstallation.NoticeBefore assembly, coat all parts with lubricant. In case of thepaper-lined blocking rings, soak them in DexronII/III beforeinstallation.

2. Assemble the following parts :1st speed blocking ring.Alignment pin and 1st speed gear bearing race.1st speed gear and its bearing.

3. Install the rear bearing assembly to the main shaft.

4. Using a hydraulic press and installer, press the 5th drivengear onto the main shaft. While the main shaft is still on thepress bed, install the 5th driven gear snap ring. If the snapring does not fit completely, continue pressing the 5th drivengear.

5. Install the following parts :2nd speed blocking ring assembly.Thrust washer for the blocking ring inner cone.Spiral retaining ring (Use special tools).2nd speed gear spacer, bearing and gear.2nd gear thrust washer and snap ring.3rd speed gear spacer, bearing and gear.3rd speed blocking ring.

MANUAL TRANSMISSION 5B-31

6. Using a hydraulic press and installer, install the 3-4synchronizer hub onto the main shaft.NoticeAlign the blocking ring with the synchronizer keys whileinstalling the hub.

5B-32 MANUAL TRANSMISSION

INPUT SHAFTDisassembly Procedure1. Remove the following parts from the input shaft :

Main shaft thrust race and bearing.Main shaft pilot bearing rollers (15 rollers).

2. Using a hydraulic press and puller plate, remove the inputshaft bearing assembly from the shaft.

3. Remove the input bearing.

4. Remove the input shaft seal.

5. Check and clean all removed parts and replace if necessary.

MANUAL TRANSMISSION 5B-33

Assembly Procedure1. Using a hydraulic press and installer, press the input shaft

bearing onto the input shaft.

2. Apply grease to the thrust bearing inner roller (15 rollers)and install the main shaft thrust bearing and its race in therear of the input shaft.

3. Using a rubber hammer and installer, install the input bearingretainer and input shaft seal after applying grease.

4. Install the bearing outer race to the retainer without endplay adjusting shim.

5B-34 MANUAL TRANSMISSION

COUNTER SHAFTDisassembly Procedure1. Using a hydraulic press and special tool, remove the front

bearing assembly from the counter shaft.

2. Check and clean all removed parts and replace if necessary.

Assembly Procedure1. Using a hydraulic press and installer, press the front bearing

assembly onto the counter shaft.

2. Install is as follows :Install a new O-ring on the counter shaft outer race andlubricate it.Using a installer, lightly tap the race into its bore until theO-ring is compressed.Install the race to be fully seated on the inside of thecase.

MANUAL TRANSMISSION 5B-35

EXTENSION HOUSINGDisassembly Procedure1. Remove the vent from the extension housing.

2. Remove the O-ring and steel ring from the rear of theextension housing.

3. Check and clean all removed parts and replace if necessary.

Assembly Procedure1. Install the O-ring and steel ring to the rear of the extension

housing.2. Install the vent to the extension housing.

5B-36 MANUAL TRANSMISSION

SHIFT COVERDisassembly Procedure1. Using a hammer and a pin punch (3/16) remove the selector

arm roll pin.

2. Before removal, note the correct position of the interlockplate and selector arm and remove the shift shaft.

3. Check and clean all removed parts and replace if necessary.

Assembly Procedure1. If the shaft cup plug was removed, apply plug outer surface

with sealer and install it into the cover.

2. Install the fork pads and selector plates onto the 1-2 and 3-4 shift forks.

3. Assemble the sift cover parts as follows :Push the shift shaft into the cover until the front of the shaftis at the inside of the cover.

MANUAL TRANSMISSION 5B-37

Install the 1-2 shift fork and its selector plate.

Push the shift shaft through the 1-2 shift fork.

Place the selector arm and interlock plate in the coverNote the position of the interlock plate and selector arm.

Push the shift shaft through the 3-4 shift fork.

5B-38 MANUAL TRANSMISSION

Install the 3-4 shift fork and its selector plate.

Push the shift shaft through the 3-4 shift fork.

Install the roll pin that fixes the selector arm to the shiftshaft.

4. Check the shift cover parts for proper assembly as follows :Insert a pin punch (3/16) into the offset lever hole ofthe shift shaft.Place the shift cover to the flat ground and rotate theshift shaft so that the punch is vertical.

MANUAL TRANSMISSION 5B-39

Selector arm should be aligned with the 3/4 shift forkselector plate.

5. Lubricate and install the O-ring on the rear of the shift cover.

5B-40 MANUAL TRANSMISSION

INSPECTION OF COMPONENTSInspection Procedure1. Clean all parts with solvent and dry them with compressed

air. Check the following parts for cracks and damagedsealing surfaces.

CaseExtension housingShift CoverInput bearing retainerCounter shaft rear bearing retainer

2. Check the parts which support bearings and shafts forexcessive wear and replace them if necessary.

3. Check the bearing surfaces of the following parts ;Input shaftMain shaft and its gearsCounter shaft and 5th drive gear

4. Check the reverse idler shaft and its gears.NoticeReplace excessive wear parts and do not file on thehardened surface and precision ground.

MANUAL TRANSMISSION 5B-41

5. Check the shift mechanism parts as follows :Wear of the shift shaft.Wear of the detent/guide plate and offset lever.

Check worn edges on the following parts :- Selector arm.- Interlock plate.- Selector plates for the 1-2 and 3-4 shift forks.

- 5-R shift lever and the rollers on the reverse fork andthe 5th shift rail/fork.

Check worn mating surfaces on the following parts :- 1-2 shift fork, pads and synchronizer sleeve.- 3-4 shift fork, pads and synchronizer sleeve.- 5th shift rail/fork pads and synchronizer sleeve.- Reverse fork and reverse idler gear sleeve.

5B-42 MANUAL TRANSMISSION

6. Check the following Bearing for excessive war:Crankshaft pilot bushing for the front of the input shaft.Clutch release bearing.Input shaft bearing.Main shaft pilot bearing rollers.Main shaft thrust Bearing and its surfaces.

Speed gear roller bearing on the main shaft.Main shaft rear bearing.Counter shaft front and rear bearings.

7. Check the gear tooth surfaces of all gear sets.

8. Check the reverse gear set surfaces. Check the surfacesof gear teeth for excessive wear, pitting, scoring and spallingand replace if necessary.

MANUAL TRANSMISSION 5B-43

9. Take apart the three synchronizer assemblies and check :The 1-2 synchronizer.

The 5th blocking ring.

10. Check the fit between the hub and sleeve of eachsynchronizer

Excessively tight or loose hub-to-sleeve fit.Wear of the cone clutch surfaces of brass blockingrings and gears.

11. Measure the clearance between the blocking ring and thespeed gear

New 1-2 blocking ring : 0.87-1.4mmNew 3-4 blocking ring : 0.88-1.5mm

NoticeExcessive wear of the blocking ring or the speed gear conesurface will cause shift block-out gear clash.

5B-44 MANUAL TRANSMISSION

12. Check for gear clash on the synchronizer sleeve teeth orthe clutch teeth on the speed gear.

13. Check the synchronizer sleeve and gear clutch tooth forhop-out.

MANUAL TRANSMISSION 5B-45

PRE-INSTALLATION CHECKSChecking Procedure1. Separate the clutch release fork from the pivot and remove

the pivot from the clutch housing.

2. Check the pivot. Fork and release bearing.

3. Check the pressure plate spring.NoticeInspect each parts and replace the excessively worn parts.

4. Check the clutch housing alignment as follows :Place the magnetic base on the pressure plate spring.

Check the housing bore alignment.- Place the dial indicator on the bore.- By rotating the crankshaft one revolution, record the

dial indicator reading.

5B-46 MANUAL TRANSMISSION

Check the housing face alignment.- Place the dial indicator on the housing face.- By rotating the crankshaft one revolution, record the

dial indicator reading.NoticeIf the reading is greater than 0.010 inch, insert the shimbetween the engine and clutch housing and adjust thealignment.

5. Check the following parts :Pressure plate spring assemblyDiscFlywheelInput shaft pilot bearing

NoticeReplace the excessively worn parts.

6. Lubricate the clutch release bearing bore, fork pivot headduring assembly.

TypeClutch Pedal

Clutch Disc

Clutch Master Cylinder

Clutch Release Cylinder

Clutch Fluid

DescriptionHydraulic

Suspended158 mm

5 - 10 mmSingle Dry Diaphragm

9.85 - 10.2 mm9.2 mm19.8 mmf15.87 mm

14.0 mmf17.46 mm

SAE J1703 / DOT3

SECTION 5C

CLUTCH

TABLE OF CONTENTSSpecifications. . . . . . . . . . . . . . . . . . . . . . . . 5C-1

General Specifications . . . . . . . . . . . . . . . . . . 5C-1Fastener Tightening Specifications . . . . . . . . . 5C-2

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . 5C-3Special Tools Table . . . . . . . . . . . . . . . . . . . . . 5C-3

Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4Clutch Slips . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4Poor Disengagement . . . . . . . . . . . . . . . . . . . 5C-4Hard to Shift or Will not Shift . . . . . . . . . . . . . . 5C-4Clutch Chatters When Starting . . . . . . . . . . . . 5C-4Difficult Pedal Operation . . . . . . . . . . . . . . . . . 5C-5

SPECIFICATIONSGENERAL SPECIFICATIONS

Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when atool or equipment could easily come in contact with exposed electrical terminals. Disconnecting thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.

Application

TypeMax. Pedal StrokePedal Free PlayTypeThickness of Disc

StrokeInner DiameterStrokeInner Diameter

FreeWith Load

Clutch Noisy . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-5Component Locator . . . . . . . . . . . . . . . . . . . 5C-6

Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . 5C-6Pedal and Master Cylinder . . . . . . . . . . . . . . . 5C-7

Maintenance and Repair . . . . . . . . . . . . . . . 5C-8On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 5C-8

Bleeding of Clutch System . . . . . . . . . . . . . . . 5C-8Clutch Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-9Master Cylinder . . . . . . . . . . . . . . . . . . . . . . 5C-13Clutch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . 5C-15Clutch Oil Chamber . . . . . . . . . . . . . . . . . . . 5C-17

5C-2 CLUTCH

FASTENER TIGHTENING SPECIFICATIONS

ApplicationClutch Cover BoltClutch Housing BoltClutch Release CylinderMaster Cylinder NutClutch Tube NutPedal Push Rod NutPedal Mounting

N·····m3747

30 - 408 - 18

15 - 1816 - 228 - 18

21 - 25Bracket BoltStopper Bolt

CLUTCH 5C-3

SPECIAL TOOLSSPECIAL TOOLS TABLE

602 589 00 40 00Engine Lock

661 589 00 15 00Centering Pin

5C-4 CLUTCH

ChecksOily FacingHard or Faulty FacingBurnt Torsion SpringFaulty Pressure PlateBent Clutch Diaphragm SpringHard or Bent FlywheelEngine Mounts Loose or Burnt Lever

ActionAdjust Pedal Freeplay

Repair Release CylinderRepair or Replace

Repair as NecessaryReplace

ChecksExcessive Clutch Pedal Free playFaulty Clutch Release CylinderWorn Disc, Excessive Run-out, Damaged LiningDirty or Burred Splines on Input Shaft or Clutch DiscDamaged Clutch Pressure Plate

ChecksVibration or Excessive Run-out of DiscRust or Wear of Disc SplineOily FacingDamaged Diaphragm SpringExcessive Clutch Pedal Free play

DIAGNOSISCLUTCH SLIPS

ChecksExcessive Wear of FacingHard or Oily FacingDamaged Pressure Plate or FlywheelDamaged or Burnt Diaphragm SpringClutch Pedal Free play InsufficientFaulty Operation of Clutch PedalWorn or Damaged Clutch Disc

ActionReplace

Repair or ReplaceReplaceReplaceAdjust

Repair or ReplaceReplace

POOR DISENGAGEMENT

ActionReplace

Repair or ReplaceRepair or Replace

ReplaceAdjust

HARD TO SHIFT OR WILL NOT SHIFT

CLUTCH CHATTERS WHEN STARTINGAction

Repair or ReplaceReplaceReplaceReplaceReplace

Repair or ReplaceTighten or Replace

CLUTCH 5C-5

ChecksPoor Lubrication on Clutch CablePoor Lubrication on Pedal ShaftPoor Lubrication on Clutch Pedal

Not Using the Clutch

After DisengagementWhen Disengaging

DIFFICULT PEDAL OPERATIONAction

Lubricate or ReplaceLubricate or Replace

Repair

CLUTCH NOISYChecks Action

AdjustReplaceReplaceReplaceRepair

Replace

Insufficient Clutch Pedal Free playExcessive Wear of FacingWorn or Damaged Release BearingPoor Lubrication Contact Surface of BearingFaulty Installation of Clutch Assembly or BearingDamaged Pilot BushingClutch Pedal is Partially Depressed

and Vehicle Speed is Reduced

5C-6 CLUTCH

COMPONENT LOCATORCLUTCH ASSEMBLY

1 Clutch Disc2 Clutch Cover3 Clutch Housing4 Release Bearing5 Release Fork Pivot6 Release Cylinder7 Release Fork Boot

8 Bolt9 Release Fork

10 Bolt11 Spring Lock Washer12 Transmission Input Spline13 Release Bearing Contacting Surface14 Contacting Point of Release Fork and Pivot

NoticeApply the long-term grease (DBL 6811.00) to No.12,13 and 14.

CLUTCH 5C-7

PEDAL AND MASTER CYLINDER

1 Clutch Pedal2 Clutch Master Cylinder3 Clutch Tube4 Clutch Oil Chamber

5 Clutch Tube6 Clutch Hose7 Clutch Release Cylinder

5C-8 CLUTCH

MAINTENANCE AND REPAIRON-VEHICLE SERVICEBLEEDING OF CLUTCH SYSTEMBleeding procedureNoticeKeep the fluid level over ‘MAX’ in reservoir duringbleeding operation.Do not let fluid contact a painted surface.1. Remove the air bolt cap of the release cylinder.

Connect a vinyl tube to the bolt.2. Insert the other end of the tube in a vacant container.3. Slowly depress the clutch pedal several times.4. With clutch pedal fully depressed, open the air bolt and

release air rind fluid in the fluid line,5. Repeat this procedure until there are no more air bubbles

in the fluid flows.

CLUTCH 5C-9

CLUTCH DISCPreceding Work : Removal of the transmission

1 Clutch Disc2 Clutch Cover Assembly3 Release Bearing4 Clutch Housing

Tools602 589 00 40 00 Engine Lock661 589 00 15 00 Centering Pin

5 Washer6 Bolt ........................................................... 23 Nm7 Washer8 Bolt ........................................................... 44 Nm

5C-10 CLUTCH

Removal & Installation Procedure1. Remove the starter motor. Install the special tool to the

flywheel through the starter motor mounting holes.

Tightening Torque 47 Nm

Engine Lock 602 589 00 40 00

2. Unscren the release cylinder mounting bolts and removethe release cylinder.Installation Notice

3. Unscrew the clutch housing bolts and remove the clutchhousing, release fork and release bearing.Installation Notice

4. Insert the centering pin into the clutch spline.Loosen the clutch cover bolts 1/2 turn in crisscross sequenceuntil the spring tension is released.NoticeDo not remove the bolts at a time, or clutchcover can bedamaged or deformed.

Centering Pin 661 589 00 15 00

Tightening Torque 30 - 40 Nm

CLUTCH 5C-11

5. Unscrew the bolts and remove the clutch cover, pressureplate and clutch disc.NoticeBe careful not to drop the pressure plate and clutch disc.Installation Notice

Tightening Torque 21 - 27 Nm

6. Installation should follow the removal procedure in thereverse order.Notice

Before installation, clean oil and grease on theflywheel surface.Do not clean the clutch disc and release bearing insolvent.

5C-12 CLUTCH

Inspection Procedure1. Clutch Cover

Check the diaphragm spring tip for wear and heightunevenness.

Check the pressure plate surface for wear, crack anddiscoloration.Check the strap plate rivet for looseness and replacethe clutch cover if loosened.

Unevenness Limit 0.8 mm

2. Clutch DiscCheck the facing for rivet looseness, excessive runout,sticks, oil and grease.Measure the rivet head depth.If out limit, replace the disc.

3. Clutch Release BearingThe release bearing is permanently lubricated andrequires no cleaning.Check the bearing for sticks, damage, abnormal noise,turning drag and wear.

4. Release ForkIf there is abnormal wear in contact point with bearing,replace the release fork.

Wear Limit 0.3 mm

CLUTCH 5C-13

MASTER CYLINDER

1 Snap Pin2 Clevis Pin3 Clevis4 Lock Nut5 Flange Nut ........................................... 30-40 Nm6 Push Rod7 Cylinder Body8 Oil Pipe ................................................ 15-18 Nm

9 Clamp10 Reservoir11 Spring12 Piston Assembly13 Boot14 Plate15 Snap Ring

NoticeDo not disassemble the No.12.

5C-14 CLUTCH

Removal & Installation Procedure1. Draw out the fluid.2. Pull out the snap pin and clevis pin from the clutch pedal

connection.3. Remove the clutch tube.

Installation Notice

Tightening Torque 15 - 18 Nm

NoticeBe careful not the fluid contact a painted surface.

4. Remove the master cylinder mounting nuts and pull off themaster cylinder.Installation Notice

Tightening Torque 8 - 18 Nm

5. Check the clutch pedal operation.6. Bleed the clutch system.

CLUTCH 5C-15

CLUTCH PEDAL

1 Snap Pin ................................................ Replace2 Clevis Pin ...................................... Apply Grease3 Master Cylinder Push Rod4 Gasket5 Nut ....................................................... 16-22 Nm6 Spring washer7 Bolt ........................................................ 8-18 Nm8 Fulcrum Pin

9 Turn Over Spring .......................... Apply Grease10 Bushing ......................... Replace, Apply Grease11 Full Stroke Stopper Contact Pad12 Clutch Pedal13 Pedal Pad14 Pedal Mounting Bracket15 Stopper Bolt .......................................... 21-25Nm16 Clutch Interlock Switch

NoticeAssembly should follow the disassembly procedure in the reverse order.Grease specification : Long - term grease (T/Mn DBL6611.00)

5C-16 CLUTCH

Inspection Procedure1. Pedal Stroke (A).

NoticeTo adjust the pedal stroke, loosen the lock nut (H) of theinterlock switch (G) and turn the two lock auto until the strokeis correct.

Max. Stroke 158 mm

2. Pedal Height (B).

NoticeTo adjust the pedal height, loosen the lock nut (C) of thestopper bolt(D) and turn the stopper bolt until the height iscorrect.

Height (From the Floor Carpet) 147 - 187 mm

3. Pedal Free Play (E).

NoticeTo adjust the pedal free play, loosen the lock nut (F) of themaster cylinder and turn the push rod until the free play iscorrect.

4. Check the fulcrum pin and the bushing for wear, the pedalfor bending and the spring for damage.

Free Play 5 - 10 Nm

CLUTCH 5C-17

CLUTCH OIL CHAMBER

1 Clutch Master Cylinder2 Hydraulic Tube3 Bolt

4 Clutch Oil Chamber5 Hydraulic Tube6 Clutch Release Cylinder

NoticeInstallation should follow the removal procedure in the reverse order.When installing, perform the bleeding procedures from chamber cylinder and release cylinder.